Roll-up door assembly

ABSTRACT

The roll-up door assembly enables the garage or shed to be used as an extra room. The assembly comprises the door cover, the opener mechanism and the frame structure. A canvas roll-up door fits over the opening of the elongated entryway of the garage. The door mechanism is similar to the mechanism on a home awing. The canvas includes screens covering window openings to enable ventlization throughout the room. The size of the window openings can be varied by employing roll-up window covers with ties to adjust temperature and airflow within the garage. Velcro® is used to affix the canvas to the side members of the frame structure of the garage. The assembly can either be installed as a unit as an attachment that fits onto the front frame structure of a conventional garage or can be integral with the existing frame structure. The opener mechanism is either manual or automatic.

FIELD OF THE INVENTION

[0001] The invention relates generally to a heavy-duty fabric-type doorcover and closure assembly for an elongated doorway, and moreparticularly, a cover mechanism to enable the conversion of a garage,porch, shed, or the like to a room structure such as a workshop, den, orrecreation room with both ventilation and privacy.

DESCRIPTION OF RELATED ART

[0002] There are numerous elongated doors, particularly for garages,made of flexible materials and related mechanisms that enable the doorto be adapted for use to a conventional garage entryway.

[0003] U.S. Pat. No. 5,323,835 (Bachmeier) discloses a removable screenthat is flexible for a car garage door opening. A Velcro®-type fasteningsystem secures the top and side edges of the screen to the garage frame.The screen can be readily applied across a conventional garage dooropening and is compatible with conventional garage doors.

[0004] U.S. Pat. No. 5,123,474 (smith) discloses a roll-up garage doorclosure device having a screen made of flexible fabric that allowsventilation therethrough but keeps out debris. The device is designedprimarily for motorized operation and includes vertical guide tracks asthe door is opened and closed.

[0005] U.S. Pat. No. 4,244,417 (Taylor) discloses a flexible door of aflexible fabric disposed onto a roller for use in large door openingssuch as airplane hangers. The door is designed to eliminate air leakagealong the sides of the doors. The upper end of the door is affixed tothe horizontal building member. A motor or hand crank is used to raiseand lower the roller, and metal brackets disposed on each side of thedoorway cooperate with the roller to maintain tension in the door coverto apply a downward force that serves to eliminate slack therein.

[0006] U.S. Pat. No. 3,693,695 (Deane) discloses a flexible-sheet thatis power-driven and adapted for a doorway while maintaining closurealong the sides of the flexible sheet. The unwound portion of the sheetremains flush against the plane of the opening in all positions of theroller, thereby preventing dust and debris from passing around the sidesof the closure sheet.

[0007] None of these mechanisms and doors provide for a heavy-duty typefabric that has good insulation properties that can be used in virtuallyall climates, and is readily adaptable for varying cross-ventilationpatterns.

[0008] What is needed is a door cover for an elongated entryway to abuilding frame structure that will enable the frame structure to be usedas an extra room such as a recreation room, a workshop, or a den whennot used for car storage; the room ensuring privacy and ventilation andsunlight as needed; what is needed is a door cover made of a materialthat has good insulation properties and is a protective barrier forintruders.

[0009] What is needed is a door cover mechanism that can be installedeither as a pre-constructed assembly onto the front of any conventionalbuilding structure or as a door opener and door cover directly onto theframe of the building structure; what is needed is a door covermechanism for a garage that is fully compatible with conventional rigidmanual and automatic garage door openers, thereby enabling conversion ofthe garage from a room to a garage and back again as needed. What isneeded is a door cover mechanism that enables an awning-type rotationalmovement of the roller relative to the elongated entryway for safetypurposes to engage and disengage the door cover relative to theelongated entryway.

[0010] What is needed is a roll-up mechanism that will enable the doorcover to be rolled-up over the elongated entryway when the door cover isnot in use and fully extended and securely retained when the door coveris in use; what is needed is a heavy-duty, low maintenance, roll-upmechanism that will support a multi-layered, rollable tarp-typematerial.

SUMMARY OF THE INVENTION

[0011] The preferred embodiment of the door assembly of the presentinvention comprises a frame structure, a door cover, and an openermechanism that is adaptable for attachment onto the outer framesurrounding an entryway of a fixed building structure.

[0012] The door cover is made of a heavy duty, fabric-type material anddisposed about a roller. The door cover is closed in the fully-extendedposition and is open in the rolled-up position. One end of the rollabledoor cover is secured to a member of the frame structure that issubstantially parallel to the roller. The door cover preferably includesa door entryway through which egress and access is enabled therethrough.The sides edges of the door cover include means for securing sideportions of the fabric material to opposing side members of the framestructure to seal the door cover and keep out unwanted debris and such.

[0013] The door cover has at least one window opening which is coveredby a screen-type material disposed therewithin, and preferably threewindow openings. The screen-type material enables ventilation whitekeeping out debris. The size of each window opening is adjustable. Acover of fabric material is securely attached above each window openingand has a rolled-up position and a fully-extended position. In therolled-up position each cover enables ventilation therethrough and inthe fully-extended position each cover preserves room temperature. Also,each window opening cover includes means for attachment to the sides ofthe window opening to the edges of the door cover proximate to thewindow opening cover when the window opening cover is in the fullyextended position so as to provide an air-tight fit, to insure privacy,and further preserve room temperature.

[0014] The door frame assembly cooperative engages the roll-up doorcover for attachment to the frame structure disposed about the elongatedentryway. The door frame assembly comprises a pair of parallel sidemembers and a cross member, a retainer affixed across the first member.The cross member is substantially normal to the side members and isdisposed across and secured to the top ends of the side members.

[0015] A retainer is positioned across the cross member and securedthereto and enables secure retention with the outermost edge of the doorcover. The retainer is an elongated channel-shaped jaw secured to andpositioned at the top of the entryway. A latch mechanism is disposedproximate to the lowermost end of at least one of the side members. Thelock mechanism enables secure retention of the door cover when the doorcover is in the fully-extended position.

[0016] The opener mechanism comprises a roller disposed between a pairof opposing sidebars. Each sidebar is secured to one of the secondarymembers. The roller sidebars are secured to the secondary members insuch a way as to enable pivotal movement of the roller relative to thesecondary members when the roller moves from the raised position to thelowered position and back again. Each sidebar is secured to thesecondary member by a sidebar extension, which is an extension of thesidebar and is substantially parallel to the roller. Each sidebarextension includes a spring-tension member. The spring-tension memberenables the roller to be in a relaxed state when in the raised positionand in tension when in a lowered position.

[0017] For a more complete understanding of the roll-up door assembly ofthe present invention, reference is made to the following detaileddescription and accompanying drawings in which the presently preferredembodiments of the invention are shown by way of example. Otheradvantages of the present invention will be readily appreciated as thesame becomes better understood by reference to the following detaileddescription when considered in connection with the accompanying drawingswherein. As the invention may be embodied in many forms withoutdeparting from spirit of essential characteristics thereof, it isexpressly understood that the drawings are for purposes of illustrationand description only, and are not intended as a definition of the limitsof the invention. Throughout the description, like reference numbersrefer to the same component throughout the several views.

DESCRIPTION OF THE DRAWINGS

[0018] The above discussion provides a factual basis for the use ofroll-up door assembly of the present invention. The methods used withand the utility of the present invention can be shown by theaccompanying figures.

[0019]FIG. 1 is an environmental view showing the roll-up door assemblyof the present invention relative to a conventional garage;

[0020]FIG. 2 is an assembly view of the roll-up door mount assembly ofthe present invention as shown in FIG. 1 in combination with a garagedoor in the down position, various positions of the door screen beingshown in phantom of the rollable door during repositioning from therolled up position to the fully-extended position;

[0021]FIG. 3 is a top view of the roll-up door assembly of the presentinvention as shown in FIG. 2 as seem looking downward from over theassembly, the assembly being in a position between the rolled-upposition and the rolled-down position;

[0022]FIG. 4 is an exploded detail view of the upper portion of theroll-up door assembly of the present invention as shown in FIG. 2, andincludes a first preferred embodiment of a retainer mechanism;

[0023]FIG. 5 is an exploded detail view of the lower portion of theroll-up door assembly of the present invention as shown in FIG. 2, andincludes a first preferred embodiment of a latch mechanism;

[0024]FIG. 6 is a front assembly view of the door cover of FIG. 1;

[0025]FIG. 7A is an exploded detail view of the roll-up window openingcover of the door cover of FIG. 6;

[0026]FIG. 7B is an exploded detail view of a second preferredembodiment of the retainer mechanism disposed relative to the crossmember of the elongated entryway of the door frame assembly of FIG. 1;

[0027]FIG. 7C is an exploded detail view of a second preferredembodiment of the latch mechanism disposed on one of the side members ofthe elongated entryway of the door frame assembly of FIG. 1; and

[0028]FIG. 7D is an exploded detail view of the opener mechanismrelative to one of the pair of opposing sidebars enabling the roll-updoor cover of FIG. 1 to pivot from a rolled-up position to thefully-extended position;

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0029] Referring now to the drawings, while the fixed building structurecan be a porch, a shed, an airplane hanger, or the like, for purposes ofillustration herein the fixed building structure is depicted as aconventional garage as shown in FIG. 1.

[0030]FIG. 2 is an assembly view of the preferred embodiment of theroll-up door assembly 10 of the present invention is shown. The roll-updoor assembly 10 comprises a frame structure 20, a door cover 30, and anopener mechanism 60 that is adaptable for attachment onto the outerframe 12 surrounding an entryway 14 of a fixed building structure 16.When applied to a conventional garage, the assembly of the presentinvention is positioned onto the outside of the garage and is fullycompatible with both conventional automatic and manual garage doors 18.

[0031] The preferred embodiment of the door cover 30 of the presentinvention is shown in FIG. 6. The door cover 30 is made of a heavy duty,canvas-type material and disposed about a roller 32, about which thedoor cover is rolled. The door cover is made from a multi-layered tarpmaterial with good insulation properties as the trapped air between thelayers enhances the insulation properties. The fabric material iswaterproof so that it can be left in the fully-extended position forlong periods of time without concern for damage from the elements. Thedoor cover 30 is closed in the fully-extended position and is open inthe rolled-up position. One end of the rollable door cover 30 is securedto a member of the frame structure 20 that is substantially parallel tothe roller 32. The vertical side edges 36 of the inner surface of thedoor cover 30 when in the fully-extended position include means such asa two-inch Velcro® strip for securing side portions of the fabricmaterial to opposing side members 24 and 25 of the frame of the entryway14 to seal the door cover 30 and keep out unwanted debris and such.

[0032] The door cover 30 of the present invention has at least onewindow opening 38 covered by a screen-type material disposedtherewithin, such as fiber-glass screening, and preferably three or morewindow openings 38. The screen-type material enables ventilationthroughout the entryway 14 while keeping out debris. A roller 40 offabric material is securely attached above each window opening 38enabling the size of each window opening 38 to be adjustable. A rollablewindow opening cover 42 has a rolled-up position, a plurality ofpartially rolled-up positions and a fully-extended position. In therolled-up position and in any of the partially rolled-up positions, eachcover 42 enables ventilation therethrough and in the fully-extendedposition prevents ventilation therethrough preserving room temperaturein the fully-extended position. The window opening cover 42 has a ropeor cord 44 disposed on the outer surface thereof for cooperativelyengaging with a loop 45 disposed on the door cover 30 to retain the doorcover 30 in the open position and to assist in retaining the openingcover 42 in any of the partially open positions.

[0033] Each window opening 38 and portions of the door cover 30proximate to the window opening 38 includes means for securing thewindow opening cover 42 to the sides of the door cover 30, such asVelcro®, When the window opening cover 42 is in the fully extendedposition the securing means provides an air-tight fit, to insureprivacy, and further preserve room temperature. Further, flexible andclear vinyl sheets 46 that also have a trim of Velcro®-type materialdisposed about the outer edge 49 thereof for cooperative engagement andsecure retention with the door cover 30 to enable natural sunlight intothe enclosed structure while preserving room temperature. The door cover30 is double-stitched for purposes of strength horizontally extendingacross the cover proximate to both the top and the bottom of the windowopenings 38. The window opening cover 42 can also be two-way mirrors toensure privacy while enabling natural sunlight to illuminate theenclosed room structure. Also, in another preferred embodiment, theflexible vinyl sheets 46 that are two way mirrors can replace theroll-up window cover 42 as a means for varying the size of the windowopening 38, since the sheets 46 can be repositioned across the windowopening 38 to vary the size of the screen opening for ventilationpurposes.

[0034] The door cover 30 preferably includes an door entrance 50 throughwhich egress and access is enabled therethrough. The entrance 50 may bea zipper-type attachment disposed on the inside surface of the doorcover 30. In another embodiment, a plurality of mechanical hookfasteners disposed on the inside of the cover for the door entrance 50and cooperatively engaging loop fasteners disposed on the inside of thecover (not shown), so as to prevent unwanted entry through the cover.

[0035] The door frame structure 20 cooperative engages the roll-up doorcover 30 for attachment to the frame structure 20 disposed about theelongated entryway 14. The door frame assembly comprises a pair ofparallel side members 24 and 25 and a cross member 26, a retainer 70affixed across the cross member 26. The cross member 26 is substantiallynormal to the side members 24 and 25, and is disposed across the topends of the side members 24 and 25 and secured thereto.

[0036]FIG. 4 discloses a first preferred embodiment of the retainer 70of the present invention. The lip 33 of the door cover 30 cooperativelyengages an elongated channel by a snap fit and is securely retainedtherewithin. FIG. 7B discloses a second preferred embodiment of theretainer 70 positioned across the cross member 26 and secured theretoand enables secure retention with the outermost edge of the door cover30. The retainer 70′ is an elongated channel 74 integral with thecross-member 26 and positioned at the top of the entryway 14. The lip 33of the door cover 30 is disposed at the edge thereof and is slightlyenlarged to enable secure retention. The retainer 70′ includes a beveledkey-way 72 to cooperatively engage a recess 73 in the door cover lip 33and securely retain the door cover lip 33 inside the retainer 70′.

[0037]FIG. 5 discloses a first preferred embodiment of a latch mechanism80 for use in the assembly of the present invention, whereby the roller32 cooperatively engages by means of a snap fit into a groove disposedin the bottom of each side member 24 and 25. FIG. 7C discloses a secondpreferred embodiment of a latch mechanism 80′ for use with the assemblyof the present invention, the latch mechanism 80′ being disposedproximate to the lowermost end of one or both of the side members 24 and25. The Latch mechanism 80′ enables secure retention of the door cover30 when the door cover 30 is in the fully-extended position. The latchmechanism 80′ includes a sliding plate 82 disposed within a groove 84 inthe side member 24 or 25. The sliding plate 82 includes a lock-nut 86that is manually released enabling the sliding plate 82 to fit into anotch 88 in the protruding flange extension disposed on the bottomsurface of the side member 24 or 25 to securely retain the door cover 30within a C-shaped recess 89 in the side member when the door cover 30 isin the fully-extended position. To close the door cover 30, the plate 82is raised and the door opener mechanism 60 is activated.

[0038] The opener mechanism 60 of the present invention comprises aroller 32 disposed between a pair of opposing sidebars 62. Each sidebar62 is secured to one of the side members 24 and 25 as shown in FIG. 3.The opener mechanism 60 enables the door cover 30 to be rotatablyrepositioned similar to the way that an awning is disposed relative to aresidential window. The sidebar extensions 65 cooperatively engage atoothed knob, thereby enabling the roller 40 to be swung in an outwardmanner and away from the frame structure 20, generally through a 180degree arc from the raised position to the lowered position and backagain. Each sidebar 62 is preferably made of aluminum and is secured oneof the side member 24 or 25 by the extensions 65. The extensions 65 aresubstantially parallel to the roller 32. Each sidebar extension 65includes a spring-tension member 64. The spring-tension member 64enables the roller 32 to be in a relaxed state when in the raisedposition and in tension when in the lowered position. The openermechanism 60 of the present invention is either manually operated ormotor controlled.

[0039] Another embodiment has the roll-up door assembly 10′ comprisesthe door cover 30 and the opener mechanism 60 disposed relative to anexisting frame structure 20. The opener mechanism is mounted onto theside members 24 and 25 of the elongated entryway 14. A roller 32 andopener mechanism 60 are disposed onto to the frame structure 20 and thedoor cover 30 is mounted onto the roller 32.

[0040] Throughout this application, various United states patents arereferenced by patent number and inventor. Full citations for thepublications are listed below. The disclosures of these patents in theirentireties are hereby incorporated by reference into this application inorder to more fully describe the state of the art to which thisinvention pertains.

[0041] It is evident that many alternatives, modifications, andvariations of the roll-up door assembly of the present invention will beapparent to those skilled in the art in light of the disclosure herein.It is intended that the metes and bounds of the present invention bedetermined by the appended claims rather than by the language of theabove specification, and that all such alternatives, modifications, andvariations which form a conjointly cooperative equivalent are intendedto be included within the spirit and scope of these claims.

1. A door cover for retention relative to a frame structure disposedabout an elongated entryway, the entryway having a frame structure, thedoor cover being made of a heavy duty, fabric-type material, thematerial being rollable about a roller, the door cover having afully-extended position and a rolled-up position, one end of the doorcover being securely retainable to a portion of the frame structure, thedoor cover having a window opening disposed therewithin, the windowopening having a size that is adjustable.
 2. The door cover of claim 1,wherein the window opening is covered by a screen-like material toprevent insects from passing therethrough.
 3. The door cover of claim 1,further comprising a window opening cover disposed proximate to thewindow opening, the window opening cover having a rolled-up position anda fully-extended position, the window opening cover in the rolled-upposition enabling ventilation therethrough.
 4. The door cover of claim3, wherein the window opening cover includes means for attachment to thesides of the window opening thereby preventing any ventilationtherethrough when the rollable sheet is in the closed position.
 5. Thedoor cover of claim 1, further comprising an entryway in the fabric-typematerial through which egress and access is enabled therethrough.
 6. Thedoor cover of claim 1, further comprising means for securing sideportions of the fabric material to opposing side members of cooperatingmembers of a frame structure.
 7. A door frame assembly enablingcooperative engagement with a roll-up door cover for attachment to aframe structure disposed about an elongated entryway, the door frameassembly comprising: a first member being disposed between a pair ofsecondary members, the pair of secondary members being substantiallyparallel to each other and substantially normal to the first member, thefirst member being disposed proximate to top ends of the pair ofsecondary members and securely retained thereto, the secondary membersbeing secured substantially to the ends of the first member; and aretainer affixed across the first member, the retainer enablingcooperative engagement and secure retention with an end of a door cover;whereby the first member is for secure attachment to a cross member of afixed building structure, and the pair of secondary members are forsecure retention to opposing sideframe members of the fixed buildingstructure.
 8. The door frame assembly of claim 7, further comprising alock mechanism disposed proximate to a bottom end of at least onesecondary member, the lock mechanism enabling secure retention of thedoor cover when the door cover is in a fully-extended position.
 9. Thedoor frame assembly of claim 7, further comprising a cooperating meansdisposed on each secondary member, the cooperating means enablingengagement with a pivoting member.
 10. The door frame assembly of claim7, wherein the retainer comprises an elongated channel-shaped jawsecured to and positioned at the top of the elongated entryway.
 11. Thedoor frame assembly of claim 7, further comprising means disposed on theside edges of the secondary members to enable cooperative engagementwith side edges of a door cover.
 12. A door cover mechanism assembly forretention relative to a frame structure disposed about an elongatedentryway, the frame structure having a cross member and opposingsecondary members, the mechanism comprising: a roller being disposedbetween a pair of opposing sidebars, the sidebars being substantiallysymmetrical to each other relative to the roller, an extensionprotruding from each sidebar, the pair of sidebar extensions beingfixedly secured relative to the frame structure, the pair of sidebarextensions being pivotally rotatable relative to the frame structure;and a door cover made of a heavy-duty fabric-type material, thefabric-type material being rollable about the roller, the door coverhaving a first end that is essentially parallel to the axis that issecurely retainable to the cross member of the frame structure, the doorcover having a fully-extended position and a rolled-up position; wherebythe pivotal rotation of the pair of sidebars enable the door cover tomove from the rolled-up position to the fully-extended position.
 13. Thedoor cover mechanism of claim 12, wherein the door cover includes awindow opening disposed therewithin, the window opening having a sizethat is adjustable.
 14. The door cover mechanism of claim 12, whereinthe window opening being covered by a screen-like material to preventinsects from passing therethrough.
 15. The door cover mechanism of claim14, further comprising a rollable sheet of fabric-type material beingpositioned relative to the window, the window opening being coveredthereby preventing ventilation therethrough when the sheet is in theclosed position, the window opening enabling ventilation therethroughwhen the rollable sheet is the open position.
 16. The door covermechanism of claim 12, wherein one end of the door cover is securedrelative to the cross member and the other end of the door cover issecured relative to at least one of the secondary members.
 17. The doorcover mechanism of claim 12, wherein each sidebar extension including aspring-tension member, the spring-tension member enabling the roller tobe relaxed when disposed in a raised position, the spring-tension memberenabling the roller to be in tension when the roller is in a loweredposition.
 18. A door mount assembly for attachment to a frame structuredisposed about an elongated entryway, the door mount assemblycomprising: a first member being disposed between a pair of secondarymembers, the pair of secondary members being substantially parallel toeach other and substantially normal to the first member, the pair ofsecondary members being substantially identical to each other, the firstmember being disposed proximate to top ends of the pair of secondarymembers and securely retained thereto, the secondary members beingsecured substantially to the ends of the first member; and an openermechanism having a roller disposed between a pair of opposing sidebars,the pair of sidebars being substantially symmetrical relative to theroller, each sidebar being secured to a secondary member, the rollerhaving a raised position and a lowered position, the roller rotatingpivotally relative to the secondary members when moving from the raisedposition to the lowered position.
 19. The door mount assembly of claim18, wherein each sidebar extension includes a spring-tension member, thespring-tension member enabling the roller to be relaxed when disposed ina raised position, the spring-tension member enabling the roller to bein tension when the roller is in the lowered position.
 20. The doormount assembly of claim 18, further comprising a retainer affixed acrossthe first member, the retainer enabling secure retention with an end ofan elongated roller edge of a fabric-type material.
 21. The door mountassembly of claim 18, wherein a lock mechanism is disposed proximate toa bottom end of one secondary member, the lock mechanism enabling secureretention with part of the roller when the roller is in the loweredposition.
 22. The door mount assembly of claim 18, wherein the firstmember is for secure attachment to a substantially horizontal crossmember of the garage frame, and the pair of secondary members are forsecure retention to the sideframe of the garage frame.
 23. A doorstructure disposed relative to an elongated entryway, the elongatedentryway including a crossframe member disposed between a pair ofsideframe members, the door structure comprising: an opener mechanismincluding a roller which moves from a raised position to a loweredposition, the roller being pivotally rotatable relative to the elongatedentryway; and the door cover being made of a heavy duty, fabric-typematerial, the material being rollable about the roller, the door coverhaving a fully-extended position and a rolled-up position, the doorcover having a first end that is essentially parallel to the roller, thefirst end being securely retainable to the crossframe member. wherebywhen the roller moves from the raised position to the lowered position,the door cover moves from the rolled-up position to the fully-extendedposition.
 24. The door structure of claim 23, wherein the door cover hasa window opening disposed therewithin, the window opening having a sizethat is adjustable.
 25. The door structure of claim 23, wherein the doorcover includes a window opening disposed therewithin, the window openingbeing covered by a screen-like material to prevent debris from passingtherethrough.
 26. The door structure of claim 23, wherein a cover offabric material is positioned relative to the window opening, the windowopening is covered thereby preventing ventilation therethrough when therollable sheet is a downward position, the window opening beingventilated when the window opening cover is an upward position.